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  1. There has been a long thread of exchanges at Timmy960's topic on harsh shifting after rebuilding an AX15 transmission. The problem around 3rd/4th gear shift issues has a basis in the redesign of the synchronizer sleeve, bronze blocking rings and the third gear cog teeth for the sleeve engagement. Jason Logan and I had an exchange about this issue when he rebuilt his '99 TJ Wrangler unit. That exchange was just prior to the launch of the forums. For the benefit of all AX15 rebuilders, I am starting a new topic around this issue, beginning with the in-depth Q&A exchange that Jason Logan
  2. Hi, Just joined but have been using these forums for a while for information. SO I have an 88 YJ with the TBI. My issue all started when I went to get it smogged last year. Short story it failed 3 times for high NOX @ 35mph. By the third failure I had replaced every sensor I could replace, including the EGR. The cataliytic converter only has about 1000 miles. I do have the snap-on diagnostic tester, just looking for some direction to narrow my troubleshooting. Currently the jeep wont idle on its own and I can smell that it is running very rich and it seems to run a bit rough. T
  3. On the passenger side engine compartment on my 89 yj 2.5 liter there is some diagnostic plug in connectors. which one is the connector for the isa motor control? Which one is D-1 and D-2? How are each individual holes in connectors numbered ( 1-2-3-4-5-6 etc>)?
  4. I recently bought a 1990 Jeep YJ with 4 cyl 2.5 TBI engine. The jeep runs great except during warm-up. It starts fine and runs and idles well initially. As soon as the temperature gauge begins to climb off the 100 degree mark, the engine begins hunting and surging and usually stalls. If I push down on the accelerator and run it to 1000+ rpm, I can get the engine to heat up to operating temperature. At that point (~160-170F) the idle becomes stable again. So far I haven't done a lot of troubleshooting but have checked the EGR valve, changed rotor/cap, air filter, and fuel filter with no s
  5. I have replaced the gasket around the dist shaft, not much more that a week later it is leaking again. I used a feel-pro gasket, I have always had good luck with them. This area of the engine isn't pressurized is it? Both surfaces were very clean when I put it together. Possible that the crankcase isn't venting?
  6. I have purchased an 87 yj tbi 2.5. With help from this site I have been tinkering with this thing trying to get it to run as its suppose to especially in this cold weather. I was looking at my egr valve while I was replacing the vacuum lines and noticed it was unhooked and the line feeding it is plugged. I did notice that the vacuum port on the egr was facing the front of the jeep, that seems to be the wrong direction to me.
  7. If you read this Moses, many thanks for your Dana 30 rebuild article, it's the only one I've found that helped me. Here is my problem in a rather large nutshell. 1995 YJ, 2.5 5spd. I had an axle seal leaking and bad lower ball joints so I figured it would be a great time to upgrade to 4:88 gears and 4340 axles since I am rolling 33-12.50's. I opened up the diff to find a recent but very poorly installed 4:56. The caps were on upside down and it had about .100" backlash so I am essentially starting from zero. The carrier bearings appear to be original so I am fairly sure the shims are clos
  8. T-shooting an intermittent starting problem. About 80% of start-ups are perfect. When failing to start, it will turn over and over, but won't fire up. Sometimes starter fluid will cause it to fire up and then it runs fine, but that's only 50% effective. The rest of the time, only push-starting will work, but push-starting does work every time. Most obvious assumption is fuel problem, but fuel system checks out fine (replaced almost everything over time anyway). Ignition/electrical is fine. Also, the problem seems to be completely independent of outside and engine temperature. I st
  9. I have a 1990 YJ and the intermittent wipers don't work I replaced the moter several months ago and just relaced the switch still no intermittent and it will not "park " the wipers to one side just where ever they are turned off any suggestions?
  10. Moses, your website has been extremely useful for me while working on my 1989 Jeep YJ Wrangler 2.5L TBI engine. I have used it for testing just about everything on my jeep. I have replaced several items because of extremely high emissions. Today was the 4th pass through the test, and I finally passed my emissions test. I have replaced the ignition coil, ignition control module, spark plugs, cap and rotor and set the base timing, map sensor (because it did not hold vacuum), coolant temp sensor and my fuel injector. With all of that, my emissions finally were within spec. I am still ha
  11. Hi, I have a 1988 Jeep Yj 2.5 with the renix computer. My last stop before I drive this thing off a cliff is here. I should have come here first. I hope one of you can help me. I love my Jeep but am so frustrated with it right now. Problem: Jeep is running super rich. I do not think it is ever coming out of closed loop. Points to know: - O2 sensor is recognizing that the jeep is rich. Volts sit between .94V and .99V JEEP RUNS AWESOME. No loss of power. No hesitation. Idles between 900 and 750 - Fuel smell coming from the tailpipe Emissio
  12. Moses and @biggman100 @BadDriver4x4 thanks for taking the time (a full year ago!) to respond to my inquiry. A little update: I found a mechanic out in Suffolk County, NY who is supposedly the local Jeep expert. I drove the hour to visit, nice guy, knows his stuff, but I think he was a bit un-enthused about me supplying all of my own parts, and he has a full schedule - and he knows that an picky, educated customer with a rusty Jeep is a bad value proposition! He never got back to me with a quote. Well, arm be damned, I decided to take my time and do the work myself. Some parts:
  13. Moses, thanks so much for responding. I’ve actually been following many of your posts and articles regarding tuning up the 2.5 TBI. I will check these posts you’ve listed and see where to go from there and provide feedback to this post. Regarding the 2nd issue (Loud sound) I’m really hoping that it’s what you say such as the driveshafts/splines and NOT my renewed motor or Tranny. The motor still goes on and sounds very smooth and the transmission changes gears smooth also. It makes sense that it is a driveshaft sound and how it Rocks the Jeep. For the first time in 27 years whi
  14. Hello, I have some trouble with mpgs, idling and acceleration on my Wrangler YJ 1995. 4.0. Recently went to a mechanic, he connected my PCM to a DRBIII scantool, and he told me that the adaptive factor is -80%. He did reset all adaptive memory, and I can feel improvement in mpg and acceleration. Is there any way to reset adaptive memory other than connecting it to a scantool? I've read on internet about touching positive and negative cables (or grounding postitve), that it empties the capacitors in PCM adaptive memory. The reason I'm asking this is because I don't have scantool availabl
  15. Hello I have a 1990 Jeep Wrangler 2.5l and I'm having a problem keeping it going it will start and I have to keep my foot in it to keep it going once I let off it will die does not idle then it will not start again what's my problem thanks?
  16. My Jeep YJ Wrangler 2.5L (MPI not TBI) engine has no fuel pressure when it cold. Installed a new fuel pump and pressure regulator, swapped relays. When the Jeep is parked inside it runs and has fuel pressure. When we put the gauge on to check fuel pressure at the rail, inside we get around 39 psi. When we let the Jeep sit outside overnight and check pressure we have none. Any ideas? Thanks.
  17. The buzzer doesnt come on any more when I put the keys in the ignition and the door is open. Same with the headlights! Is there a way to test the buzzer and its connector?
  18. Hello, first off let me begin by saying thank you to Moses for your site. It has helped me fix a lot of issues with my jeep. I have a 1988 jeep yj with the renix 2.5 tbi setup. The problem is that the jeep starts and runs but consistently spit, sputters and stalls. I can be driving down the road doing 55 mph and then it is like somebody turns the key off and back on again. it does this at idle as well. Things I have already done/replaced: new cap, rotor, plugs, wires, coil, ign. Module, ign. Switch, and the cps. I have gone through and tested the coolant temp sensor (for the ecu
  19. In the second pic I know the line at arrow #1 goes to the air cleaner. Can anyone tell me where #2 and #3 should go? first pic is just a close up of the connections in question. Thanks
  20. Looking for info on this swap... I have a air leak in my 83 CJ power brake booster, i need a new or reman booster of course but im thinking take the opportunity to upgrade (if it is one). Anybody done this YJ to CJ booster swap or have good info please share. thanks
  21. Hi, I've been dealing with an overheating behavior in my YJ 1989 Wrangler (4.2L with all emissions control hooked up except pulse air system, Carter BBD, Auto Trans). Long time ago I've replaced cooling fluid, It was 100% tap water that is the worst choice due to corrosion; so I decided to replace it by an ethylene glycol mix as you can find them ready to pour into your cooling system. I don't know if the coolant was poor quality but immediately after replacing the fluid I was getting the engine overheated. Perhaps it was air trapped in the system as the guy replacing the coolant did all the p
  22. Hi, I have a '89 Wrangler with the 2.5l. It pops/backfires back up through the intake whenever I give it throttle. There are no vacuum leaks. I have replaced every sensor. I have swapped out the PCM, no change. I have checked fuel pressure, 15 psi. At this point I found excessive play in the distributor when rotating the crank, so I pulled the timing cover and found the chain to be stretched, and the cam sprocket and crank sprocket timing marks were mis-aligned. Aha! I said, and replaced the timing set- I set the crank to #1 TDC on compression, rotated the cam forward so that the marks would l
  23. Hi Moses I purchased your AX-15 rebuild video on vimeo. I also downloaded the AX-15 service manual before I started this project. When I started this project it was supposed to be a simple clutch install. How ever when I removed the transmission from the Jeep which is a 93 YJ Sahara. I noticed that the pilot bearing had grenaded and part of the inner race had welded its self to the input shaft on the transmission. I figured since I will have to tear the transmission down to replace the input shaft I might as well do a full rebuild since I had noticed some grinding going into 3
  24. '91 YJ . Move the transfer case lever to 4h, the front axle engages and the indicator light comes on. All works fine at slow speeds, but as speed increases (toward 40 mph) the indicator light will flick off and then back on accompanied by "clunk" noise from the front and slight jerk felt in the chassis. Since the shift motor only has 2 vacuum lines, I assume that one applies vacuum for engagement and the other vacuum for disengagement. Both lines lead to the control switch on the transfer case. I suspect the control switch is failing. Any thoughts.
  25. We have a 1990 Jeep Wrangler YJ, 2.5, Throttle Body, 5 speed. Sometime when we shift gears and accelerate it chokes down, like it isn't getting enough gas. We have tried cleaning the Throttle Body, the crankshaft speed sensor, changed fuel filter, cleaned air cleaner and ran sea foam through it. It still does it. Also, sometimes, when you start it, it dies then it starts really hard, lots of cranking, it is almost like it floods. Any suggestions? Thoughts?
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